CYLINDER BLOCK
EM-79
< SERVICE INFORMATION >
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
DISASSEMBLY
NOTE:
Explained here is how to disassemble with engine stand supporting transmission surface. When using differ-
ent type of engine stand, some steps may be different.
1. Remove engine assembly and mount to engine stand. Refer to EM-74, "
Removal and Installation".
CAUTION:
Before removing the hanging chains, make sure engine stand is stable and there is no risk of over-
turning.
2. Drain engine oil. Refer to LU-9, "
Changing Engine Oil".
3. Drain engine coolant by removing the cylinder block drain plugs
“A”, “B”, “C” and “D” as shown.
4. Remove the following components and associated parts (the parts referred to in step 1 are not included
here).
• Oil pan (upper and lower) and oil strainer. Refer to EM-24, "
Removal and Installation".
• Crankshaft pulley, front cover and timing chain. Refer to EM-38, "
Removal and Installation".
• Camshaft. Refer to EM-46, "
Removal and Installation".
• Cylinder head. Refer to EM-65, "
Removal and Installation".
5. Remove knock sensor and sub harness.
CAUTION:
Carefully handle sensor, avoiding shocks.
6. Check connecting rod side clearance. Refer to EM-93, "
Inspection After Disassembly".
7. Remove piston and connecting rod assembly as follows.
a. Position the crankshaft pin corresponding to the connecting rod to be removed onto bottom dead center.
b. Remove connecting rod cap.
22. Drive plate 23. Reinforcement plate 24. Rear oil seal retainer
25. Rear oil seal 26. Transmission 27. O-ring
28. Crankshaft position sensor (POS) 29. Gasket 30. Cylinder block heater
31. Connector cap
WBIA0419E
KBIA2549E
EM-82
< SERVICE INFORMATION >
CYLINDER BLOCK
ASSEMBLY
1. Fully air-blow the coolant and oil passages in the cylinder block, cylinder bore, and crankcase to remove
any foreign material.
CAUTION:
Use goggles to protect your eyes.
2. Install each plug to the cylinder block (only screw-type plugs are
shown).
• Apply liquid gasket.
Use Genuine Thread Sealant or equivalent. Refer to GI-45,
"Recommended Chemical Product and Sealant".
• Replace copper washers with new ones.
• Tighten each plug as specified below.
3. Install main bearings and thrust bearings.
a. Remove any dust, dirt, and oil on the bearing mating surfaces of
the cylinder block and main bearing caps.
b. Install thrust bearings to both sides of the No. 3 journal housing
on the cylinder block and main bearing caps
• Install thrust bearings with the oil groove facing the crankshaft
arm (outside).
• Install thrust bearings with a protrusion in the center on the
main bearing caps.
c. Install main bearings paying attention to the direction.
• Install the one with oil holes onto the cylinder block and the
one without oil holes onto the main bearing cap.
• Before installing bearings, apply engine oil to bearing surface
(inside). Do not apply oil to the back surface, but thoroughly
clean it.
• When installing, align the bearing stopper to the notch.
• Ensure the oil holes on the cylinder block and those on the
corresponding bearing are aligned.
4. Install pilot converter to the crankshaft using suitable tool.
5. Install crankshaft to the cylinder block.
• While turning crankshaft by hand, make sure it turns smoothly.
Part Washer Tightening torque
A Yes 53.9 N·m (5.5 kg-m, 40 ft-lb)
B No 19.6 N·m (2.0 kg-m, 15 ft-lb)
C Yes 62.7 N·m (6.4 kg-m, 46 ft-lb)
D Yes 62.7 N·m (6.4 kg-m, 46 ft-lb)
WBIA0419E
PBIC0093E
PBIC0094E
EMP0569D
FSU-2
< SERVICE INFORMATION >
PRECAUTIONS
SERVICE INFORMATION
PRECAUTIONS
PrecautionINFOID:0000000003532631
• When installing the rubber bushings, the final tightening must be done under unladen condition and with the
tires on level ground. Oil will shorten the life of the rubber bushings, so wipe off any spilled oil immediately.
• Unladen condition means the fuel tank, engine coolant and lubricants are at the full specification. The spare
tire, jack, hand tools, and mats are in their designated positions.
• After installing suspension components, check the wheel alignment.
• Lock nuts are not reusable. Always use new lock nuts for installation. New lock nuts are pre-oiled, do not
apply any additional lubrication.
SERVICE DATA AND SPECIFICATIONS (SDS)
FSU-19
< SERVICE INFORMATION >
C
D
F
G
H
I
J
K
L
MA
B
FSU
N
O
P
SERVICE DATA AND SPECIFICATIONS (SDS)
General SpecificationINFOID:0000000003532647
Spring Free HeightINFOID:0000000003532648
Wheel Alignment (Unladen*1) *6INFOID:0000000003532649
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
*2: Target value 37° 31′ (37.52°)
*3: Target value 33° 59′ (33.98°) Suspension type Independent double wishbone coil over shock
Shock absorber type Double-acting hydraulic
StabilizerStandard equipment
2WD325.5 ± 3 mm (12.8 ± 0.1 in)
4WD335.0 ± 3 mm (13.2 ± 0.1 in)
Drive type2WD 4WD
Camber
Degree minute (decimal degree)Minimum -0° 51′ (-0.85°)-0° 33′ (-0.55°)
Nominal -0° 6′ (-0.10°)0° 12′ (0.20°)
Maximum 0° 39′ (0.65°)0° 57′ (0.95°)
Cross camber 0° 45′ (0.75°) or less 0° 45′ (0.75°) or less
Caster
Degree minute (decimal degree)Minimum 3° 15′ (3.25°)2°45′ (2.75°)
Nominal 4° 0′ (4.00°)3° 30′ (3.50°)
Maximum 4° 45′ (4.75°)4° 15′ (4.25°)
Cross caster 0° 45′
(0.75°) or less 0° 45′ (0.75°) or less
Kingpin inclination
Degree minute (decimal degree)13° 32′ (13.53°)13°13′ (13.22°)
Total toe-inDistance (A − B)Minimum 1.8 mm (0.07 in) 1.8 mm (0.07 in)
Nominal 2.8 mm (0.11 in) 2.8 mm (0.11 in)
Maximum 3.8 mm (0.15 in) 3.8 mm (0.15 in)
Angle (left side or right side)
Degree minute (decimal degree)Minimum 0° 3′ (0.05°)0° 3′ (0.05°)
Nominal 0° 5′ (0.08°)0° 5′ (0.08°)
Maximum 0° 7′ (0.12°)0° 7′ (0.12°)
Wheel turning angle
(full turn)Inside
Degree minute (decimal degree)34° 31′ – 38° 31′ *2
(34.52° – 38.52°)34° 44′ – 38° 44′ *4
(34.73° – 38.73
°)
Outside
Degree minute (decimal degree)30° 59′ – 34° 59′ *3
(30.98° – 34.98°)30° 29′ – 34° 29′ *5
(30.48° – 34.48°)
SFA234AC
FSU-20
< SERVICE INFORMATION >
SERVICE DATA AND SPECIFICATIONS (SDS)
*4: Target value 37° 44′ (37.73°)
*5: Target value 33° 29′ (33.48°)
*6: Some vehicles may be equipped with straight (non-adjustable) lower link bolts and washers. in order to adjust camber and caster on
these vehicles, first replace the lower link bolts and washers with adjustable (cam) bolts and washers.
Ball JointINFOID:0000000003532650
*1 Measure at cotter pin hole
*2 Measure at groove
Wheelarch Height (Unladen*1)INFOID:0000000003532651
Unit: mm (in)
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
*2: Verify the vehicle height. If vehicle height is not within ± 10 mm (0.39 in) of the specification, perform the control unit initialization pro-
cedure. Refer to RSU-42, "
Initialization Procedure". Swinging force “A”Upper ball joint 8.1 – 103.2 N (0.8 – 10.5 kg-f, 1.8 – 23.2 lb-f) *1
Lower ball joint 11.4 – 145.5 N (1.1 – 14.8 kg-f, 2.5 – 32.7 lb-f) *2
Turning torque “B” 0.5 - 6.4 N·m (0.05 - 0.65 kg-m, 4 - 57 in-lb)
Vertical end play “C”0 mm (0 in)
SFA858AWEIA0076E
Suspension type
Air leveling*2
Applied model 2WD 4WD
Front wheelarch height (Hf)913
(35.94)931
(36.65)
Rear wheelarch height (Hr)912
(35.91)932
(36.69)
LEIA0085E
GI-50
< SERVICE INFORMATION >
TERMINOLOGY
TERMINOLOGY
SAE J1930 Terminology ListINFOID:0000000003531507
All emission related terms used in this publication in accordance with SAE J1930 are listed. Accordingly, new
terms, new acronyms/abbreviations and old terms are listed in the following chart.
NEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM
Air cleaner ACL Air cleaner
Barometric pressure BARO ***
Barometric pressure sensor-BCDD BAROS-BCDD BCDD
Camshaft position CMP ***
Camshaft position sensor CMPS Crank angle sensor
Canister *** Canister
Carburetor CARB Carburetor
Charge air cooler CAC Intercooler
Closed loop CL Closed loop
Closed throttle position switch CTP switch Idle switch
Clutch pedal position switch CPP switch Clutch switch
Continuous fuel injection system CFI system ***
Continuous trap oxidizer system CTOX system ***
Crankshaft position CKP ***
Crankshaft position sensor CKPS ***
Data link connector DLC ***
Data link connector for CONSULT-II DLC for CONSULT-II Diagnostic connector for CONSULT-II
Diagnostic test mode DTM Diagnostic mode
Diagnostic test mode selector DTM selector Diagnostic mode selector
Diagnostic test mode I DTM I Mode I
Diagnostic test mode II DTM II Mode II
Diagnostic trouble code DTC Malfunction code
Direct fuel injection system DFI system ***
Distributor ignition system DI system Ignition timing control
Early fuel evaporation-mixture heater EFE-mixture heater Mixture heater
Early fuel evaporation system EFE system Mixture heater control
Electrically erasable programmable read
only memoryEEPROM ***
Electronic ignition system EI system Ignition timing control
Engine control EC ***
Engine control module ECM ECCS control unit
Engine coolant temperature ECT Engine temperature
Engine coolant temperature sensor ECTS Engine temperature sensor
Engine modification EM ***
Engine speed RPM Engine speed
Erasable programmable read only memory EPROM ***
Evaporative emission canister EVAP canister Canister
Evaporative emission system EVAP system Canister control solenoid valve
Exhaust gas recirculation valve EGR valve EGR valve
IDX-3
A
C
D
E
F
G
H
I
J
K
L B
IDX
ALPHABETICAL INDEX
Brake fluid level ................................................. MA-28
Brake hydraulic line ........................................... BR-12
Brake inspection ................................................ MA-28
Brake lines and cables inspection ..................... MA-28
Brake master cylinder ....................................... BR-15
Brake switch ...................................... EC-572, EC-584
BRK/SW - Wiring diagram ............................... EC-585
Bulb specifications ........................................... LT-148
Bumper, front ...................................................... EI-13
Bumper, rear ....................................................... EI-15
C
Cabin air filter .................................................... MA-21
Camshaft ........................................................... EM-46
Camshaft inspection .......................................... EM-49
Camshaft position sensor (PHASE) ................ EC-369
CAN - Wiring diagram .............. EC-157, AT-93, AT-94
CAN communication EC-32, EC-156, EC-159, TF-112,
RSU-6
Canister-See EVAP canister ............................. EC-36
Center case (Transfer) ....................... TF-154, TF-167
CHARGE - Wiring diagram ............................... SC-19
Charging system ............................................... SC-17
Chassis and body maintenance ........................ MA-21
Chassis and body maintenanceSchedule 1 ........ MA-8
Chassis and body maintenanceSchedule 2 ...... MA-10
CHIME - Wiring diagram ..................................... DI-41
Circuit breaker ................................................... PG-17
Clock ................................................................... DI-61
CLOCK - Wiring diagram .................................... DI-61
Closed loop control ............................. EC-26, EC-501
Closed loop control (Bank 1) ........................... EC-501
Closed loop control (Bank 2) ........................... EC-501
Clutch drum (Transfer) ....................... TF-154, TF-167
Clutch pressure switch (Transfer) ...... TF-154, TF-167
Coil spring (front) ............................................. FSU-10
Collision diagnosis .......................................... SRS-53
Combination lamp, front, removal and installation . LT-
25
Combination lamp, rear, removal and installation .. LT-
101
Combination meter ................................................ DI-5
Combination switch ............................................ LT-79
COMBSW - Wiring diagram ............................... LT-79
COMM - Wiring diagram ................................... AV-94
COMPAS - Wiring diagram ................................. DI-24
Compass ............................................................. DI-23
Component Location (auto A/C) ...................... ATC-38
Compressor clutch removal and installation . ATC-180
Compressor mounting ................................... ATC-179
Compressor precaution ................................... ATC-11
Compressor special service tool ..................... ATC-14
Condenser ..................................................... ATC-184
Connecting rod .................................................. EM-96
Connecting rod bearing clearance .................... EM-96
Connecting rod bushing clearance .................... EM-96
Console box - See Instrument panel ................... IP-10
CONSULT for VDC ......................................... BRC-27
CONSULT general information ........................... GI-37
CONSULT-II for engine ................................... EC-118
Control units (terminal arrangement) ................. PG-71
Control valve (A/T) ............................................. AT-36
Control valve (Transfer) ...................... TF-154, TF-167
Converter housing installation ............ AT-240, AT-244
COOL/F - Wiring diagram ................................ EC-507
Coolant mixture ratio ......................................... MA-12
Coolant replacement ............................ CO-10, MA-13
Cooling circuit (engine) ........................................ CO-8
Cooling fan ........................................................ CO-17
Cooling fan control ........................................... EC-504
Cooling fan motor ............................................ EC-513
Cooling unit (A/C evaporator) ....... ATC-157, ATC-186
Corrosion protection ......................................... BL-157
Crankcase ventilation system - See Positive crankcase
ventilation .......................................................... EC-46
Crankshaft ......................................................... EM-79
Crankshaft position sensor (POS) ................... EC-362
Crash zone sensor .......................................... SRS-48
CUR/SE - Wiring diagram ... EC-522, EC-529, EC-536,
EC-543
Cylinder block .................................................... EM-78
Cylinder block boring ......................................... EM-99
D
D/LOCK - Wiring diagram ................................... BL-19
Data link connector for Consult ......... EC-120, EC-132
Daytime light system .......................................... LT-27
Daytime running light - See Daytime light system .. LT-
27
DEF - Wiring diagram ....................................... GW-74
Diagnosis sensor unit ...................................... SRS-51
Diagnostic trouble code (DTC) for OBD system . EC-9,
EC-54
Diagnostic trouble code (DTC) inspection priority chart
EC-91
Differential carrier assembly ............................ RFD-15
Differential gear oil replacement ........................ MA-26
Dimensions ......................................................... GI-51
Direct clutch solenoid valve ................ AT-143, AT-145
Display and amp.assembly .............................. ATC-59
Display Control Unit ........................................... AV-83
Display Unit ....................................................... AV-83
Dome light - See Interior lamp .......................... LT-110
Door glass .......................................... GW-62, GW-65
Door lock .......................................................... BL-121
Door mirror lamp ............................................... LT-110
Door trim .............................................................. EI-32
Door, front ........................................... BL-117, GW-62
Door, rear ........................................... BL-117, GW-65
Drive belt ........................................................... EM-13
Drive chain (Transfer) ......................... TF-149, TF-176
Drive pinion diff. inspection .............................. RFD-18
Drive shaft (rear) ................................................ RAX-7
Driver air bag ................................................... SRS-39
DTC work support ............................................ EC-128
DTRL - Wiring diagram ....................................... LT-31
IDX-4
ALPHABETICAL INDEX
Duct and grilles .............................................. ATC-170
DVD - Wiring Diagram ....................................... AV-75
DVD Entertainment System ............................... AV-72
DVD Player ........................................................ AV-73
E
ECM input/output signal ..................... EC-109
, EC-133
ECM power supply ............................. EC-150, EC-475
ECM relay ........................................................ EC-150
ECM/PW - Wiring diagram ............................... EC-476
ECTS - Wiring diagram .................................... EC-220
Electric sunroof .................................................. RF-10
Electric throttle control actuator ......... EC-595, EC-606
Electrical load signal circuit .............................. EC-657
Electrical units location ...................................... PG-65
Electronic ignition (EI) system ........................... EC-27
Engine control circuit diagram ......................... EC-107
Engine control component parts location ........... EC-98
Engine control module (ECM) .......................... EC-479
Engine control system diagram ......................... EC-24
Engine coolant .................................................. CO-10
Engine coolant temperature sensor (ECTS) ... EC-218,
EC-231
Engine fail-safe system ...................................... EC-93
Engine oil ............................................................. LU-8
Engine oil filter replacement ............................. MA-17
Engine oil precautions .......................................... GI-7
Engine oil replacement ..................................... MA-17
Engine removal ................................................. EM-74
Engine room cover ............................................ EM-12
Engine serial number .......................................... GI-50
ETC1 - Wiring diagram .................................... EC-596
ETC2 - Wiring diagram .................................... EC-591
ETC3 - Wiring diagram .................................... EC-602
EVAP canister .................................................... EC-36
EVAP canister purge volume control solenoid valve ....
EC-395
, EC-403
EVAP canister vent control valve ....... EC-410, EC-417
EVAP control system (small leak) diagnosis .. EC-387,
EC-441
, EC-449
EVAP control system pressure sensor .... EC-424, EC-
427, EC-433
EVAP control system purge flow monitoring diagnosis
EC-382
EVAP vapor lines inspection ............................. MA-20
Evaporative emission (EVAP) system ............... EC-33
Evaporator ..................................................... ATC-186
Exhaust manifold .............................................. EM-21
Exhaust system ................................................... EX-3
Exhaust system inspection .................................. EX-3
Expansion valve ............................................. ATC-188
F
F/FOG - Wiring diagram ..................................... LT-56
F/PUMP - Wiring diagram ................................ EC-666
Final drive pre-inspection ................................. FFD-15
Final drive removal and installation .. FFD-12, RFD-13
Flow charts .......................................................... GI-27
Fluid temperature sensor (A/T) ........................ AT-123
Fluids ................................................................ MA-11
Fluorescent leak detector .............................. ATC-189
Fog lamp, front ................................................... LT-54
Fog lamp, front, removal and installation ........... LT-62
Foot lamp ......................................................... LT-111
Freeze frame data ............................... EC-55, EC-121
Front brake solenoid valve ................. AT-139, AT-141
Front bumper ...................................................... EI-13
Front case (Transfer) .......................... TF-149, TF-176
Front combination lamp removal and installation LT-25
Front door ............................. BL-117, BL-121, GW-62
Front Door Trim ................................................... EI-32
Front drive shaft (Transfer) ................. TF-149, TF-176
Front fog lamp .................................................... LT-54
Front fog lamp removal and installation ............. LT-62
Front passenger air bag .................................. SRS-43
Front seat ........................................................... SE-89
Front seat belt ...................................................... SB-3
Front seat belt pre-tensioner ............... SRS-3, SRS-50
Front washer ...................................................... WW-4
Front wiper ......................................................... WW-4
FTS - Wiring diagram ....................................... AT-124
FTTS - Wiring diagram ...................... EC-334, EC-339
Fuel cut control (at no load high engine speed) EC-28
Fuel filter replacement ......................................... FL-5
Fuel gauge ............................................................ DI-5
Fuel injection system (Bank 1) .......... EC-311, EC-322
Fuel injection system (Bank 2) .......... EC-311, EC-322
Fuel injector .................................................... EC-659
Fuel injector and fuel tube ................................. EM-31
Fuel level sensor ................. EC-458, EC-460, EC-462
Fuel line inspection .............................................. FL-4
Fuel precautions ................................................... GI-5
Fuel pressure check .......................................... EC-82
Fuel pressure release ....................................... EC-82
Fuel pump ....................................................... EC-665
Fuel pump and gauge .......................................... FL-5
Fuel system .......................................................... FL-4
Fuel tank ............................................................ FL-10
Fuel tank temperature sensor ........... EC-332, EC-338
Fuel tank vacuum relief valve ........................... EC-36
FUELB1 - Wiring diagram ................. EC-313, EC-324
FUELB2 - Wiring diagram ................. EC-315, EC-326
Fuse ...................................................... PG-17, PG-77
Fuse and fusible link box .................................. PG-77
Fuse block ......................................................... PG-76
Fusible link ............................................ PG-17, PG-77
G
Garage jack and safety stand ............................. GI-42
Gauges ................................................................. DI-5
Generator .......................................................... SC-17
Generic scan tool (GST) ................................. EC-131
Glass ...................................... GW-11, GW-62, GW-65
Glove box lamp ................................................ LT-131
GPS antenna ..................................................... AV-82